Ceramics. Clays

1. Ceramics

2. Ceramics

A wide-ranging group of materials
whose ingredients are clays, sand and
felspar.

3. Clays

Contain some of the following:
Silicon & Aluminium as silicates
Potassium compounds
Magnesium compounds
Calcium compounds
Sand contains Silica and Feldspar or
Aluminium Potassium Silicate.

4. Types of Ceramics

Whitewares
Refractories
Glasses
Abrasives
Cements

5. Comparison metals v ceramics

Metals
Ceramics

6. Bonded Clay Ceramics

Made from natural clays and mixtures
of clays and added crystalline
ceramics.
These include:
Whitewares
Structural Clay Products
Refractory Ceramics

7. Whitewares

Crockery
Floor and wall tiles
Sanitary-ware
Electrical porcelain
Decorative ceramics

8. Whiteware: Bathrooms

9. Slip Casting

Sinter
and
Serve

10. Whitewares

11. Refractories

Firebricks for furnaces and ovens.
Have high Silicon or Aluminium oxide
content.
Brick products are used in the
manufacturing plant for iron and steel,
non-ferrous metals, glass, cements,
ceramics, energy conversion,
petroleum, and chemical industries.

12. Refractories

Used to provide thermal protection of other
materials in very high temperature applications,
such as steel making (Tm=1500°C), metal foundry
operations, etc.
They are usually composed of alumina
(Tm=2050°C) and silica along with other oxides:
MgO (Tm=2850°C), Fe2O3, TiO2, etc., and have
intrinsic porosity typically greater than 10% by
volume.
Specialized refractories, (those already mentioned)
and BeO, ZrO2, mullite, SiC, and graphite with low
porosity are also used.

13. Refractory Brick

14. Amorphous Ceramics (Glasses)

Main ingredient is Silica (SiO2)
If cooled very slowly will form crystalline structure.
If cooled more quickly will form amorphous structure
consisting of disordered and linked chains of Silicon
and Oxygen atoms.
This accounts for its transparency as it is the crystal
boundaries that scatter the light, causing reflection.
Glass can be tempered to increase its toughness and
resistance to cracking.

15. Glass Types

Three common types of glass:
Soda-lime glass - 95% of all glass,
windows containers etc.
Lead glass - contains lead oxide to
improve refractive index
Borosilicate - contains Boron oxide,
known as Pyrex.

16. Glasses

Flat glass (windows)
Container glass (bottles)
Pressed and blown glass (dinnerware)
Glass fibres (home insulation)
Advanced/specialty glass (optical
fibres)

17. Glass Containers

18. Pressed Glass Processing

Softened
Gob

19. Blow Molding

Softened
glass

20. Glass in Buildings

21. Plate Glass Drawing Processes

22. Tempered Glass

Small Scratches
The strength of glass
can be enhanced by
inducing compressive
residual stresses at the
surface.
The surface stays in
compression - closing
small scratches and
cracks.

23. Hardening Processes

Tempering:
– Glass heated above Tg but below the softening point
– Cooled to room temp in air or oil
– Surface cools to below Tg before interior
– when interior cools and contracts it draws the exterior
into compression.
Chemical Hardening:
– Cations with large ionic radius are diffused into the
surface
– This strains the “lattice” inducing compressive strains
and stresses.

24. Armoured Glass

Many have tried to
gain access with golf
clubs and baseball bats
but obviously the glass
remains intact ! From
time to time a local TV
station intends to show
videos of those trying
to get at the cash!!

25. Leaded Glass

26. Crystalline Ceramics

Good electrical insulators and refractories.
Magnesium Oxide is used as insulation
material in heating elements and cables.
Aluminium Oxide
Beryllium Oxides
Boron Carbide
Tungsten Carbide.
Used as abrasives and cutting tool tips.

27. Abrasives

Natural (garnet, diamond, etc.)
Synthetic abrasives (silicon carbide,
diamond, fused alumina, etc.) are
used for grinding, cutting, polishing,
lapping, or pressure blasting of
materials

28. Cements

Used to produce concrete roads, bridges,
buildings, dams.

29. Advanced Ceramics

Advanced ceramic materials have been developed over the
past half century
Applied as thermal barrier coatings to protect metal
structures, wearing surfaces, or as integral components by
themselves.
Engine applications are very common for this class of
material which includes silicon nitride (Si3N4), silicon carbide
(SiC), Zirconia (ZrO2) and Alumina (Al2O3)
Heat resistance and other desirable properties have lead to
the development of methods to toughen the material by
reinforcement with fibers and whiskers opening up more
applications for ceramics

30. Advanced Ceramics

Structural: Wear parts, bioceramics, cutting
tools, engine components, armour.
Electrical: Capacitors, insulators, integrated
circuit packages, piezoelectrics, magnets
and superconductors
Coatings: Engine components, cutting tools,
and industrial wear parts
Chemical and environmental: Filters,
membranes, catalysts, and catalyst supports

31. Engine Components

Rotor (Alumina)
Gears (Alumina)

32. Turbocharger

Ceramic Rotor

33. Ceramic Brake Discs

34. McLaren Mercedes Benz

35. Silicon Carbide

Automotive
Components in
Silicon Carbide
Chosen for its heat
and wear resistance

36. Ceramic Armour

Ceramic armour systems are used to protect military
personnel and equipment.
Advantage: low density of the material can lead to weightefficient armour systems.
Typical ceramic materials used in armour systems include
alumina, boron carbide, silicon carbide, and titanium
diboride.
The ceramic material is discontinuous and is sandwiched
between a more ductile outer and inner skin.
The outer skin must be hard enough to shatter the projectile.

37.

Most of the impact energy is absorbed by the fracturing of
the ceramic and any remaining kinetic energy is
absorbed by the inner skin, that also serves to contain
the fragments of the ceramic and the projectile
preventing severe impact with the personnel/equipment
being protected.
Alumina ceramic/Kevlar composite system in sheets
about 20mm thick are used to protect key areas of
Hercules aircraft (cockpit crew/instruments and
loadmaster station).
This lightweight solution provided an efficient and
removable/replaceable armour system. Similar systems
used on Armoured Personnel Carrier’s.

38. Ceramic - Composite Armor

Outer hard
skin
CeramicDiscontinuous
Projectile
Personnel
and
Equipment
Inner
ductile
skin
Ceramic Armor System

39. Silicon Carbide

Body armour and
other components
chosen for their
ballistic properties.